Form for molding precast concrete window frames



T. L. M KINLEY FORM FOR MOLDING PRECAST CONCRETE WINDOW FRAMES Jan. 30,1951 5 Sheets-Sheet 1 Filed April 19, 1949 Fie.4.

INVENTOR.

Tom L. MS'KINLEY,

A TTOLNEY- Jan. 30, 1951 T. L. MOKINLEY 21,539,917

FORM FOR MOLDING PRECAST CONCRETE WINDOW FRAMES Filed April 19, 1949 5Sheets-Sheet 2 f 52 {I 3 3 5.2

Z40 a T 41 F 6 [I 23 34 E8 8 INVENTOR. THOMAS L. M K\NLEY,

LATQL A TTORNEY Jan. 30, 1951 T. L. M KINLEY FORM FOR MOLDING PRECASTCONCRETE WINDOW FRAMES Filed April 19, 1949 5 Sheets-Sheet 5 Fica.8.

6:6 "llh J INVENTOR. THOMAS L. M KINLEY FiehioQ A rrore/vEY.

Patented Jan. 30, 1951 UNITED STATES FATENT 'OFFICE FOR-M FOR MOLDINGPRECAST CONCRETE WINDOW FRAMES Thoin'as L. McKinley, Miami, Fla.

Application April 19,1949, Serial No. 88,467

stop ribs for the attachment of stock size metal windows and embeddedanchor bolts for the attachment of the metal frame and the conventionalVenetian blind guide.

Another object or the invention resides in the novel construction of theform, having side and end channels and a two part core member-held inpredetermined spaced relation to the side and end channels, togetherwith the novel manner of removing the forms after the concrete hassufficiently hardened without danger of chipping or in any other wayinjurin "the cast product.

Another and novel object or the invention resides in the manner oraccurately positioning anchor bolts to project into the space to beoccupied by the concrete.

Another and important object of the invention resides in a sectional andcollapsible concrete frame mold adapted to form "a multiple number ofprecast window frames by the employment of eXtended outer header andsill channels for the reception of 'a plurality -'of core members andspacers between the core 'I'n'emb'ers corresponding in cros sectionconfiguration to the jain b channels and the novel manner of retainingthe ever'al parts in operative position against movement during thepouring of the concrete.

Various other important objects and advah tages of the invention willreadily present themselves during thecourse or the followingdescription, reference being had to the accompanying drawings, whereinis illustrated the preferred embodiments of the device.

Referring to the drawings:

Figure l is a plan view of an assembled form ready for pouring concrete,

Figure 2 is a side elevation thereof,

Figure 3 is an enlarged fragmentary section illustrating a manner orsupporting an anchor bolt,

Figure 4 is an enlarged vertical and tore'short 2 ened section through"a concrete window frame as formedby the invention,

Figure 5 is a transverse section taken on line E 5 of Figure 2,

Figure 6 is a longitudinal section taken on line 6-43 of Figure 1,

Figure 7 is "a fragmentary perspective View of two adjacent ends ofouter side and end channels,

Figure 8 is a modified form "of the invention illustrating a multipleform,

Figure 9 is a fragmentary section takenon line e e of Figure 8 and,

Figure 10 is a fragmentary transverse section through a side channel onFigure 8, with a separator member in spaced relation.

Like numerals are employed to designate like parts throughout theseveral figures of the drawmgs.

Referring specifically to the drawings, the numeral 5 indicatesa lowercore member, as a whole, generally rectangular in shape and the numeral5 indicates a co-acti'ng core member as a whole, adaptedto rest upon thelower member 5, in use.

The core member 6 is likewise generally rectangular in shape. The coremembers '5 and 9 present an open frame, the upper member li resting uponthe member 5, while the member 5 is reinforced and supported upon asuitable tablahot shown, such as the well known vibrating table. Thecore members are formed of a suitable gauge sheet metal.

The core member 5, see particularly Figures 5 and 6, is provided withinclined side walls I, an incli'ned header wall 8 and an inclined sillwall 9. The walls 1 provide a predetermined angular wall or jamb it tothe finished frame, illustrated in Figure 4, while the walls 8 and 9provide a predetermined angular finished surface to the header it andsill l2 of the frame of Figure 4. Each of the side walls l, 8 and 9 areout turned at their lower ends to form relatively wide horizontal shelfextensions i3, of a width determined by the inner facing i i of the castframe of Figure 4. The material is then bent downwardly on an angle ofninety degrees to form a vertical wall it, then bent "inwardly to form ahorizontal wall it and then upwardly parallel with the wall l5, as atIt, terminating at the first bending of the side walls, where theterminal edge is welded, 'at E8. The box-like structure formed by thewalls l3, l5, l6 and it, extends entirely around the core memher 5,providing a very rigid support for the core and associated elementsagainst downwardly flexing due to the weight of the mass of concretepoured in the form. The walls I and 8 adjacent their upper portions, arefurther inclined inwardly at an angle from the walls 7 and 3, as at it,for forming a bevelled face 25 on the inner surface of the frame ofFigure 4. From the bevel 55, the material of the core is bent upwardlyon an angle parallel with the walls I and 3 to form an annularsupporting flange 2|. The wall 9, adjacent its top, is bent inwardly atan abrupt angle to form a horizontal ledge 22 and then upwardly at anangle corresponding to the angle of and parallel with the wall 9, as at23, where it joins the flange 25 at either side, thus describing agenerally rectangular frame. The ledge 22 provides a relatively abruptshoulder 2 for the frame of Figure l, against which the conventionaltile sill finish is abutted.

The flanges 2i and 23 provide a supporting rest for the upper coremember 6. The core member is of generally channel shape, having a.downturned vertical flange 25, having outside dimensions that permit ofa relatively close lit with the opening formed by the flanges 2i and 23.The material of the core is then pressed outwardly to form a horizontalwall section 25, that extends beyond the outer edges of the flanges 2|and 23 a distance correspondin to the required depth of abutment rib 21for the cast window, as in Figure 4. From the wall 25, see Figure 5, thecore material is bent upwardly and outwardly at an angle, as at 28, toprovide bevelled side jambs for the cast window. The material of thecore 5, as in Figure 6, is bent upwardly and inwardly at an angle, as at29, to form an inward bevel 36 for the head portion of the cast windowof Figure 4, as a means of preventing a flow of Water toward the metalsash.

From the wall 26 and opposite to the wall 29, the material of the core 6is bent upwardly and outwardly at an angle, as at 3!, to provide abevelled outer sill portion 32 for the frame of Figure 4. Each of thewalls are joined at their corners, by welding into a unitary structurewhile the material is bent inwardly to form a horizontal top portion 33,terminating in a downwardly extending annular flange 34. The severalflanges and novel bending of the side walls provides a very rigidstructure against warping or twisting and will maintain its shape undermost severe handling.

It becomes necessary to the installation of metal sash in precast windowframes, to provide a means of attachment for the sash and, to providefor this contingency, a plurality of anchor bolts are provided, to becast in the frame. Similar bolts are provided for attachment of theconventional guide channels for Venetian blinds. The anchor bolts, seeparticularly Figure 3, are preferably T--shap;d, as at 35, having ahollow screw-threaded shank 35, for the reception of form mountingscrews 31. For the blind guides, the walls I are provided with equallyspaced openings 38 for the passage of the screws 37, and for the sashattaching anchors, the flanges 2!, 23 and 25 are aligned drilled for thepassage of the screws 37. In use, the anchor bolts 35 are positionedover the openings and securely held by the screws 37, as clearly shownin Figures 3, 5 and 6, with the bolts extending into the opening for thereception of the concrete. The screws 31 employed in mounting the anchorbolts for the sash, serve, not only to support the bolts, but furtherserve to prevent displacement of the upper core member 6 from itsposition of rest upon the lower core member 5.

. 42 and 33, having inner walls parallel with the wall 40 and 4| andconnected with the walls 40 and 4! by angle walls 44 and 45. The ribs,in use, provide channels around the entire frame, as at it, in Figure 4.The purpose of the channels in the frame is to provide interlockingmortar joints between the frame and the main walls of the building. Eachwall 40 and M, at its upper edge, is bent outwardly to form a horizontalwall 41, that has its terminal edge bent downwardly to form a verticalflange 48. The lower portion of each wall 46 and ll is turned inwardlyto form horizontal walls 49 and 59, adapted to rest, in use, upon thewalls I3. The width of the walls 45} and 53 corresponds to the upperwidth of the walls l3 and in use, with the side forms resting upon thewalls IS, the walls 50 and 4| lie flush with the walls l5, thus placingthe entire weight of the concrete mass upon the box-like structuredefined by the walls l3, l5, l6 and IT. A plurality of shortplates 5|are welded to the plates 55 and project upward beyond the walls l3 toserve as a means of preventing distortion outwardly of the side formsunder the pressure of the concrete. Each end form member is cut away forthe width of its rib at each end to permit snug engagement with thecorresponding rib of the side forms. Each end member is provided withhook bolts 52 adapted to engage in openings 53 formed in the horizontalwalls 41 of the side forms.

In use, the core member 5 is placed in position upon a suitable table,such as a vibrator, with its box-like base resting firmly and evenlythereon. The anchor bolts for the blind guides are then placed inposition. The upper core memher 6 is then placed upon the flange 2| andthe anchor bolts for the sash assembled. The outer forms 38 and 39 arethen placed in position, with their lower walls 49 and 50 resting uponthe walls l3 and held against spreading by the plates 5|. The placin ofthe side forms in position, causes the hook bolts to engage in theirrespective openings 53, thus securely locking the upper corners of theouter forms together. Concrete, of a suitable mix is then poured intothe form and the whole vibrated to produce a dense mass. Aftersuflicient time has elapsed to permit hardening, the upper core member 6is released, by first removing the screws 31, after which it mav beeasily lifted from its position. The screws 3'! for the blind guideanchors are likew se removed and the unit is ready for removal from thecore 5 and the removal of the side forms.

It is essential, that means be provided to give an initial lifting ofthe cast frame and its side forms, in order to release the side formsfrom their retaining plates 5! and to permit disenga ement of the hookbo ts 52. To assist in this lifting, levers 5 3, hin ed upon cross pins55 are mounted in the boxing of the lower core member 5, to swing in a,vertical plane. These levers are preferablv mounted, one at each cornerof the boxing and project outwardly of the boxing, where they areprovided with foot engaging ends 56, for engagement by the foot of theoperator.

5, The inner ends of the levers are curved and terminate in a verticalrod that projects through openings formed in the wall it for engagementwith the underside of the walls 45 and 59-. Pres sure upon the footengaging ends 56, causes the rods 5? to raise the outer formsu-fliciently far, carrying with it the cast frame, to permit the outerforms to be moved outwardly from their engagement with the plates 51.After the side. forms have thus been released, they may be disengagedwith each other and the cast frame is now ready for removal from thelower core to a place of curing. since the anchor bolts are embedded inthe cast frame, they will be ready at all times for the assembly of thesash and the blind guides. The device is now ready for cleaning andreuse. The boX-iike support for the lower core presents a very rigidbase that supports the entire weight of the forms and the mass ofconcrete poured therein and permits of the forms being supported on astructure other than a flat table, without warping or twisting, whilethe plates 5i and the hook bolts prevent side expansion of the outerforms. The inclined wails l, 8 and 9 permit ready and unobstructedremoval of the cast frame from the core 5.

Figures 8, 9 and 10 illustrate a multiple form, employing identical coreforms 5 and 5. Outer lamb forms 36, identical with the forms 38 areemployed at each end of the structure. the form as a whole is extendedin length to accommodate a plurality of core members, it follows, thatthe header and sill outer forms $9 must of necessity be of greaterlength. In all other respects, the forms 39' are identical as to crosssectional shape. The outer forms 38 and 39 are held at their corners bythe same hook bolts 52, while the same retaining plates 5! are employedto prevent spreading of the forms. In using this form of the invention,the core members are assembled and placed side to side in abuttingrelation, see Figure 9. The jamb for is 33' are then placed in positionupon their re spective plates it. Since it is not practicable to employthe jamb forms 33 between the respec tive core assemblies, spacer forms58 are employed. These spacer forms extend the entire width between theforms 39 and are likewise cut away at 59 to engage over the ribs 43' ofthe forms 39. Hook bolts to, welded to the upper edges of the spacers58, project outwardly and are adapted, at assembly to engage in openings5i, formed in the forms 39'. Each spacer has a duplicate face, andcomprises a double ribbed wall (52, corresponding to the ribs formed onthe outer forms 38' and 39'. Lower horizontal extensions 53, projectoutwardly to compl tely overlie the walls It.

After the lamb forms til have been placed in position, as before stated,the spacers are arranged in a corresponding manner and the forms 39 arethen positioned upon their respective plates it, behind the plates 5|and the several hook bolts connected in their respective openings. Theform is now ready for pouring. will be apparent, that the hook bolts65.! will prevent any spreading of the side forms 39. In other respects,the form is rigidly held against warping or twisting under the weight ofthe concrete mass. shown in this latter form of the invention, mayobviously be employed, if desired.

It will be apparent from the foregoing, that an exceptionally novel andhighly rigid form has been provided for the casting of concrete windowince The lifting levers 54, while not frames or the like. Theconstruction permits of a quick and easy assembly of the several partsanda removal of the finished product with a. minimum of effort. Theforms are constructed: in a simple manner calculated to give the properand desirable contour to the frame, yet will read-. ily disengagethemselves from the cast frame without injury thereto. The device isvery strong, relatively cheap to manufacture and ishighly eflicient inuse, resulting in the produc tion of a considerably larger number offrames in a given time.

It is to be understood, that the invention is not limited to the precisestructural details shown, but that it includes within its purview,whatever changes fairly come within either the terms or the spirit ofthe app-ended claims.

Having described my invention, what I claim as new and desire to secureby Letters Patent is:

1. A sheet metal concrete form comprising a generally rectangular lowercore member open at top and bottom and having inwardly inclined side andend walls and an annular angular flange ofiset inwardly from the sidewalls, said core having its lower portion bent outwardly to form anannular horizontal supporting base, said base bent to box-like shape forrigid support of the core, a co-acting upper core member of sheet metalformed rectangular in shape and open at top and bottom, said upper coremember provided with a depending flange adapted to be positioned withinthe flange of the lower core member, said upper core member overlyingthe upper end of the lower core member and having inclined side and endwalls, outer spaced side and end forms cooperating with the core membersand having vertical walls pressed inwardly throughout their length toform mortar grooves in the concrete, said outer forms being of a heightcorresponding to the joint height of the cores, said outer forms havingtheir lower ends bent in wardly to form horizontal support plates of awidth corresponding to the base, hook bolts for connecting the outerforms at their corners and retaining plates carried by the base toprevent lateral movement of the outer forms.

2. A concrete form of sheet metal comprising a lower core member and aupper core member superimposed thereon, the lower core member havingside and end walls having their lower ends bent to form a box-like basehaving a horizontal supporting surface projecting beyond the wallsthroughout its circumference, the side walls of the lower core adjacenttheir tops being bent inwardly at an abrupt angle and terminating in aninwardly offset flange parallel with the side walls, one end wall bentinwardly adjacent its top at approximately a right angle and then bentupward to correspond to the flange, the said cores open at top andbottom, said upper core corresponding in shape to the lower core andhaving a flat top and a depending flange adapted to engage within theflange area of the lower core, said upper core having two side and oneend wall inclined outwardly and one end wall inclined inwardly, saidupper core open at top and bottom, said flanges overlapping and providedwith aligned openings, screw devices passing through the openings, sideand end forms adapted to cooperate with the cores and comprisingvertical walls having a horizontal wall bent therefrom at their lowerends of a width corresponding to the width of the supporting surface ofthe base, the upper longitudinal edges of the forms bent to channel formoutwardly, said form Walls pressed inwardly throughout their length toform longitudinally extending ribs, the ribs of the ends and sides beingin registry, hook bolts for locking the corners of the outer formstogether, stop plates carried by the base and projecting upwardly abovethe base for overlying the lower ends of the outer forms and a pluralityof lifting devices carried by the base for engagement with thehorizontal walls of the side forms.

3. A form for molding precast window frames comprising a core and outerside forms, said core and said forms made of sheet metal, said coreformed in two parts and separable, said core being of generallyrectangular shape in top plan and having flat inwardly inclined sidewall terminating at their lower ends in box-like bases extendingentirely around the core and projecting outwardly therefrom with a flathorizontal top, the outer side forms having vertical side wall pressedinwardly throughout their length to form ribs, certain of the outer formside wall cut away to fit the rib of its adjacent side wall, hook boltscarried by certain of the side forms, with other of the side forms beingprovided with openings for the reception of the hook bolts, the sideforms having their lower ends bent inwardly at a right angle to formhorizontal support plates, said plates being of a width corresponding toand adapted to be supported upon the flat top of the base, stop plateswelded to the base and overlying the lower portions of the side formsand lifting devices carried by the base for engagement with the supportplates, said form being demountable from a casting therein.

4. A form for precast concrete window frames comprising a lowerrectangular core open at top and bottom and an upper core rectangular inshape to be superimposed on the lower core, the lower core havinginwardly inclined side walls terminating at their lower ends in abox-like l reinforced base extending entirely around the core and havinga fiat horizontal supporting face extending beyond the core, the saidwalls terminating at their upper ends in an inwardly offset fiangeparallel with the side walls, said upper core having inclined side wallsterminating in depending flange adapted to engage within the flange ofthe lower core, said flanges provided with aligned openings for thereception of screw devices, the upper portion of the upper core bentinwardly and downwardly to channel form having a flat top, separableside forms spaced from the cores and provided with horizontal supportingplates to be supported upon the base, upstanding vertical side wallscarried by the plates and having their upper edges bent outwardly anddownwardly to form a flat surfaced channel top, the vertical side wallsthroughout their length being pressed inwardly to form wide ribs spacedintermediate the height of the walls, the ribs of two side forms beingcut away to engage over the ribs of the adjacent form, hook boltscarried by certain of the forms for engaging in openings formed in theadjacent forms, stop plates carried by the base to partially overlie thevertical walls of the side forms, lifting levers pivotally supported inthe base and projecting outwardly thereof, foot pedals carried by thelevers, lifting rods formed on the levers and adapted to project throughopenings formed in the supporting face and anchor bolts supportedoutwardly of the inclined walls of the lower core adjacent the lowerends.

5. A form for the multiple casting of concrete window frames comprisinga plurality of two part demountable core members superimposed one uponthe other, said core members provided with an extended reinforced baseentirely around each one and adapted to be arranged side by side withtheir adjacent bases in abutting relation, a pair of outer side formsspaced from the outermost cores and provided with lower foot extensionswholly supported upon the adjacent bases, a pair of outer spacedelongated end forms extending between the side forms and provided withlower foot extensions wholly supported on the bases of the plurality ofcores, means for locking the corners of the outer forms together, meanscarried by the several bases to prevent displacement of the footextensions therefrom, wide ribs formed upon the side forms andprojecting inwardly toward the cores, spacer forms positioned betweenthe abutting cores and extending from one end form to the other, hookbolts carried by the spacers for engagement within openings formed inthe end forms, said spacers provided with oppositely extending wide ribsthroughout their lengths corresponding to the ribs of the outer formsand co-extensive therewith, the ends of the spacers being cut away toengage ove the ribs of the end forms, the oppositely extending ribs ofthe spacer forms being an equal distance from the cores as the side formribs, foot extensions carried by the spacer forms upon opposite sidesfor completely overlying the adjacent bases of the cores and whollysupported on the bases, each side of the spacer forms being identical insize and cross-sectional area to the side and end outer forms.

THOMAS L. McKINLEY.

REFERENCES CITED The following references are of record in the file ofthis patent:

UNITED STATES PATENTS Number Name Date 877,874 Tsanoff Jan. 28, 19081,051,568 Emtman Jan. 28, 1913 1,479,298 Hatch Jan. 1, 1924 1,569,513McClain et a1. Jan.12 1926 2,228,123 McMurray Jan. 7, 1941

